Toyota Avalon 2006 User Manual

FOREWORD

This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA AVALON.

Applicable models: GSX30 series

This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding.

When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength.

Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations.

For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA AVALON refer to the repair manuals.

If you require the above manuals, please contact your TOYOTA Dealer.

All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.

VIEWS OF THIS TEXT

Scope of the repair work explanation

 This text explains the welding panel replacement instructions from the vehicle’s white body condi-

tion. W e have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

Section categories

 Each section has been divided as shown below.

Section Title Contents Examples

INTRODUCTION

BODY PANEL REPLACEMENT

BODY DIMENSIONS Body aligning measurements. Dimension diagrams.

PAINT  COATING

Explanation of general body repair. Views of weld panel replacement instructions.

Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts.

Scope and type of anti-rust treatment, etc. together with weld panel replacement.

Abbreviation of contents in this text.

 The following essential procedures have been abbreviated. When actually working, conduct this

work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection.

Cautionary items. Views of weld panel replacement instructions.

Front side member replacement. Quarter panel replacement.

Under coat. Body sealer.

Glass Cover

INTRODUCTION

GENERAL REPAIR INSTRUCTIONS

1. WORK PRECAUTIONS

(a) VEHICLE PROTECTION

(1) When welding, protect the painted surfaces, windows,

seats and carpet with heat resistant, fire-proof covers.

IN-1

WRONG

Seat Cover

F10001A

(b) SAFETY

(1) Never stand in direct line with the chain when using a

puller on the body or frame, and be sure to attach a safety cable.

F10002A

(2) Before performing repair work, check for fuel leaks.

If a leak is found, be sure to close the opening totally.

(3) If it is necessary to use a flame in the area of the fuel

tank, first remove the tank and plug the fuel line.

WRONG

F10003A

F10004A

(c) SAFETY WORK CLOTHES

(1) In addition to the usual mechanic’s wear, cap and

safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands.

Code Name

A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves

IN-2

INTRODUCTION

2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS

(1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-

ing etc.), consideration must be given to the property of the plastic.

*

Heat

Code

Material

name

resistant temperature limit C (F)

Resistance to

alcohol or gasoline

Notes

AAS

ABS

AES

ASA

CAB

EPDM

FRP

Acrylonitrile Acrylic Styrene

Acrylonitrile Butadiene Styrene

Acrylonitrile Ethylene Styrene

Acrylonitrile Styrene Acrylate

Cellulose Acetate

Ethylene Propylene

Fiber Reinforced Plastics

80

(176)

80

(176)

80

(176)

80

(176)

80

(176)

100

(212)

180

(356)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.

Alcohol and gasoline are harmless. Avoid alkali.

Avoid gasoline and organic or aromatic solvents.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

EVA

E/VAC

PA

PBT

PC Polycarbonate

*Temperatures higher than those listed here may result in material deformation during repair.

Ethylene Acetate

Ethylene/ Vinyl Acetate Copolymer Resin

Polyamide (Nylon)

Polybutylene Terephthalate

70

(158)

70

(158)

80

(176)

160

(320)

120

(248)

Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol and gasoline are harmless. Avoid battery acid.

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol is harmless.

Avoid gasoline and organic or aromatic solvents.

Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.

Code

Material

name

*

Heat

resistant

temperature

limit C (F)

INTRODUCTION

Resistance to

alcohol or gasoline

IN-3

Notes

PE Polyethylene

PET

PMMA

POM

PP Polypropylene

PPF

PPO

PS Polystyrene

Polyethylene Terephthalate

Polymethyl Methacrylate

Polyoxymethylene (Polyacetal)

Composite Reinforced Polypropylene

Modified Polyphenylene Oxide

80

(176)

75

(167)

80

(176)

100

(212)

80

(176)

80

(176)

100

(212)

60

(140)

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol and gasoline are harmless. Avoid dipping in water.

Alcohol is harmless if applied only for short time in small amounts.

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol is harmless.

Alcohol and gasoline are harmless if applied only for short time in small amounts.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Gasoline is harmless if applied only for quick wiping to remove grease.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

PUR Polyurethane

PVC

SAN

TPO

TPU

TSOP

UP

Polyvinylchloride (Vinyl)

Styrene Acrylonitrile

Thermoplastic Olefine

Thermoplastic Polyurethane

TOYOTA Super Olefine Polymer

Unsaturated Polyester

80

(176)

80

(176)

80

(176)

80

(176)

80

(176)

80

(176)

110

(233)

Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease).

Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol and gasoline are harmless. Avoid alkali.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Avoid dipping or immersing in alcohol, gasoline, solvents etc.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

*Temperatures higher than those listed here may result in material deformation during repair.

IN-4

INTRODUCTION

3. LOCATION OF PLASTIC BODY PARTS

Parts Name Code Radiator Grille ABS Front Bumper Cover TSOP Front Bumper Hole Cover PC/ABS Headlight PP/PC Foglight PC/PE Cowl Top Ventilator Louver TSOP Door Window Frame Moulding ASA Door Outside Handle PA Outer Rear View Mirror ABS  PPO Door Outside Moulding TPO Body Rocker Panel Moulding TPO Rocker Panel Moulding Protector PP License Plate Light PC Rear Combination Light PMMA/ASA Rear Light PMMA/ASA Rear Bumper Cover TSOP

HINT:

 Resin material differs with model.

/ Made up of 2 or more kind of materials.

INTRODUCTION

HOW TO USE THIS MANUAL

1. BODY PANEL REPLACEMENT THIS MANUAL

IN-5

F13890A

IN-6

INTRODUCTION

F13891A

INTRODUCTION

IN-7

2. SYMBOLS

The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required.

F13893A

IN-8

INTRODUCTION

SYMBOLS MEANING ILLUSTRATION

—

Assembly Mark

BODY SEALER

(Flat Finishing)

BODY SEALER

(No flat Finishing)

—

F13894A

INTRODUCTION

3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE:

IN-9

F13892A

IN-10

Cutting Okay

Reinforcement

INTRODUCTION

PROPER AND EFFICIENT WORK PROCEDURES

1. REMOVAL

(a) PRE-REMOVAL MEASURING

(1) Before removal or cutting operations, take measure-

ments in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame.

F10007A

(b) CUTTING AREA

(1) Always cut in a straight line and avoid reinforced area.

WRONG

Corners

F10008A

(c) PRECAUTIONS FOR DRILLING OR CUTTING

(1) Check behind any area to be drilled or cut to insure

that there are no hoses, wires, etc., that may be damaged.

HINT: See “Handling Precautions on Related Components” on page IN-15.

F10009A

(d) REMOVAL OF ADJACENT COMPONENTS

(1) When removing adjacent components, apply protec-

tive tape to the surrounding body and your tools to prevent damage.

HINT: See “Handling Precautions on Related Components” on page IN-15.

F10010A

Less than 3 mm

F10011A

F10012A

INTRODUCTION

2. PREPARATION FOR INSTALLATION

(a) SPOT WELD POINTS

(1) When welding panels with a combined thickness of

over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding.

HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick.

(b) APPLICATION OF WELD-THROUGH PRIMER

(SPOT SEALER) (1) Remove the paint from the portion of the new parts

and body to be welded, and apply weld-through primer.

IN-11

Air Saw

Puncher

20 − 30 mm

F10013A

F10014A

Overlap

(c) MAKING HOLES FOR PLUG WELDING

(1) For areas where a spot welder cannot be used, use a

puncher or drill to make holes for plug welding.

REFERENCE: mm (in.)

Thickness of welded portion Size of plug hole

1.0 (0.04) under 5 (0.20) ø over

1.0 (0.04) − 1.6 (0.06) 6.5 (0.26) ø over

1.7 (0.07) − 2.3 (0.09) 8 (0.31) ø over

2.4 (0.09) over 10 (0.39) ø over

(d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-

PONENTS (1) When welding, there is a danger that electrical compo-

nents will be damaged by the electrical current flowing through the body.

(2) Before starting work, disconnect the negative terminal

of the battery and ground the welder near the welding location of the body.

(e) ROUGH CUTTING OF JOINTS

(1) For joint areas, rough cut the new parts, leaving 20 −

30 mm (0.79 − 1.18 in.) overlap.

F10015A

IN-12

INTRODUCTION

Body Measurement Diagrams

WRONG

3. INSTALLATION

(a) PRE-WELDING MEASUREMENTS

(1) Always take measurements before installing under-

body or engine components to insure correct assembly. After installation, confirm proper fit.

F10016A

(b) WELDING PRECAUTIONS

(1) The number of welding spots should be as follows.

Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs.

(2) Plug welding should be done with a MIG (Metal Inert

Gas) welder. Do not gas weld or braze panels at areas other than specified.

F10017A

(c) POST-WELDING REFINISHING

(1) Always check the welded spots to insure they are se-

cure.

(2) When smoothing out the weld spots with a disc grind-

er, be careful not to grind off too much as this would weaken the weld.

CORRECT WRONG

New Spot

Old Spot Locations

Locations

F10018A

(d) SPOT WELD LOCATIONS

(1) Try to avoid welding over previous spots.

F10020A

(e) SPOT WELDING PRECAUTIONS

(1) The shape of the welding tip point has an effect on the

strength of the weld.

(2) Always insure that the seams and welding tip are free

of paint.

Tip Cutter

F10019A

INTRODUCTION

IN-13

Sealer Gun

4. ANTI-RUST TREATMENT

(a) BODY SEALER APPLICATION

(1) For water-proofing and anti-corrosion measures, al-

ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc.

F10021A

(b) UNDERCOAT APPLICATION

(1) To prevent corrosion and protect the body from dam-

age by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings.

F10022A

5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS

(a) ANTI-RUST AGENT (WAX) APPLICATION

(1) To preserve impossible to paint areas from corrosion,

always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.

F10023A

IN-14

INTRODUCTION

6. ANTI-RUST TREATMENT BY PAINTING

REFERENCE:

Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described.

(a) ANTI-CHIPPING PAINT

(1) To prevent corrosion and protect the body from dam-

age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.

HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.

 Apply the anti-chipping paint after

the top coat.

Anti-Chipping Paint Top Coat

Second Coat Under Coat (ED Primer) Steel Metal

 Apply the anti-chipping paint before

the second coat.

Top Coat Second Coat

Anti-Chipping Paint Under Coat (ED Primer)

Steel Metal

F10024A

INTRODUCTION

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. BRAKE SYSTEM

The brake system is one of the most important safety components. Always follow the directions and notes given in brake (32) section of the repair manual for the relevant model when handling brake system parts.

NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.

2. DRIVE TRAIN AND CHASSIS

The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment.

HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section.

IN-15

Component to be aligned

Front Wheels Front Suspension (26) section

Rear Wheels Rear Suspension (27) section

Section of repair manual

for relevant model

3. COMPONENTS ADJACENT TO THE BODY PANELS

Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.

 Before repairing the body panels, remove their components or apply protective covers over the com-

ponents.

 Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool

tip or blade to prevent damaging the components and the body paint.

 Before removing components from the outer surface of the body, attach protective tape to the body to

ensure no damage to painted areas.

HINT: Apply touch-up paint to any damaged paint surfaces.

 Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.

4. ECU (ELECTRONIC CONTROL UNIT)

Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.

 Before starting electric welding operations, disconnect the negative (−) terminal cable from the bat-

tery. When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.

 Do not expose the ECUs to ambient temperatures above 80C (176F).

NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.

 Be careful not to drop the ECUs and not to apply physical shocks to them.

IN-16

INTRODUCTION

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

1. HEAT REPAIR FOR BODY STRUCTURE PANELS

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or ot h e r heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized.

2. STRUCTURE PANEL KINKS

A sharp deformation angle on the panel that cannot be returned to its original shape by pulling or hammering is called kink. Since structure parts are designed to exhibit its performance in their original shape, if parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred.

INTRODUCTION

3. IMPACT BEAM REPAIR

The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passengers in side collisions. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Since these parts are designed to exhibit its performance in their origi n a l shape, if parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may become unable to exhibit the same performance as intended in the design. If the impact beam or bracket is damaged, replace the door assembly which has the damaged beam. Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.

IN-17

IN-18

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this manual.

ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 2WD Two Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without

BODY PANEL REPLACEMENT

FIT STANDARDS

3.7 mm

IN-81

4.2 mm

5.4 mm

5.75 mm

4.8 mm

4.2 mm

5.2 mm

3.7 mm (0.146 in.) 4.2 mm (0.165 in.) 4.8 mm (0.189 in.)

5.2 mm (0.205 in.) 5.4 mm (0.213 in.) 5.75 mm (0.226 in.)

F22065

IN-82

BODY PANEL REPLACEMENT

3.7 mm

4.5 mm

5.75 mm

3.7 mm (0.146 in.) 4.5 mm (0.177 in.) 5.75 mm (0. 226 in.)

F22066

BODY PANEL REPLACEMENT

RADIATOR UPPER SUPPORT (ASSY)

REPLACEMENT

REMOVAL

BP-1

F22067A

F22067

BP-2

BODY PANEL REPLACEMENT

INSTALLATION

 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension

diagram. (See the body dimension diagram)

 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the

finish.

 After welding, apply the polyurethane foam to the corresponding parts.  After welding, apply body sealer and under-coating to the corresponding parts.  After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

F22068

POINT

1 Inspect the fitting of the headlight, front fender and hood, etc., before welding, since this affects the appear-

ance of the finish.

PART NAME

[A] Radiator Support Apron Brace

BODY PANEL REPLACEMENT

1,425 mm

1,210 mm

BP-3

POINT

1 Measure the dimensions before installing the headlight. 2 These values are reference values.

296 mm (11.65 in.) 480 mm (18.90 in.) 866 mm (34.09 in.) 1,210 mm (47.64 in.)

F22069

1,425 mm (56.10 in.)

BP-4

BODY PANEL REPLACEMENT

RADIATOR SIDE SUPPORT (ASSY)

REPLACEMENT

With the radiator upper support removed.

REMOVAL

F22070A

F22070

BODY PANEL REPLACEMENT

BP-5

INSTALLATION

 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension

diagram. (See the body dimension diagram)

 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the

finish.

 After welding, apply the polyurethane foam to the corresponding parts.  After welding, apply body sealer and under-coating to the corresponding parts.  After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

PART NAME

[A] Front Bumper Upper Arm

F22071

[B] Front Bumper Side Support

BODY PANEL REPLACEMENT

FRONT CROSSMEMBER (ASSY)

REPLACEMENT

REMOVAL

BP-7

F22072A

F22072

BP-8

BODY PANEL REPLACEMENT

INSTALLATION

 Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension

diagram. (See the body dimension diagram)

 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the

finish.

 After welding, apply the polyurethane foam to the corresponding parts.  After welding, apply body sealer and under-coating to the corresponding parts.  After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

10 mm (0.39 in.)

F22073

BP-8

BODY PANEL REPLACEMENT

RADIATOR SUPPORT (ASSY)

REPLACEMENT

REMOVAL

F22074A

F22074